Method of constructing with concrete



July 21, 1931. c. BRADLEY ,8

METHOD OF CONSTRUCTING WITH CONCRETE Filed Dec. 18, 1925 4 Sheets-Sheet 1 [In/en for 41.4 A4.

July 21, 1931. c. BRADLEY 4 1,815,491

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METHOD OF OONSTRUCTING WITH CONCRETE Filed Dec.. 18, 1926 4 Sheets-Sheet 4 Patented July 21, 1931 PATENT OFFICE CLAUDE BRADLEY, OF SEATTLE, WASHINGTON METHon or CONSTRUGTING WITH CONCRETE Application filed December 18, 1926.

This invention relates in general to the subject of plastic concrete construction and more particularly to a novel and practical method of supporting and holding in position the form or concrete retaining elements and the reinforcing steel when the same is to be used.

lVhereas re-usable forms of various designs supported and held in position by various methods are now only economically used when there is much repetition or upon continuous structures of more or less constant section and whereas certain methods have been invented in which permanent metal concrete-retaining elements are used which become a permanent part of the structure. This invention enables either afore-said re-usable or afore-said permanent forms or concrete retaining elements, or else either re-usable or permanent forms that may be specially devised for use with the present invention, to be economically used in constructing irregular or non repetition work such as dwellings of varied designs with almost the same case that the carpenter constructs framed and studded walls.

Another object of the present invention is to provide a construction in which the vertical metal elements which are used to support concrete retaining elements become embedded in the concrete and permanently remain there reinforcing the concrete; or in case of reinforced work, take the place of all or a part of the vertical reinforcement.

A further object of the present invention is to provide a construction in which the above mentioned vertical elements lend themselves admirably for hollow wall 7 construction formed with the aid of either removable or permanent cores or for walls embodying permanent solid cores. p

A further object of the present invention is that it permits inexpensive monolithic construction of artistic domestic buildings practically indestructible by decay, earthquake, fire or storm. 1

With the above and other objects in view which will more readily appear as the nature of the present invention is better understood, this invention comprises novel methods, combinations and arrangements of parts Serial No. 155,713.

hereinafter more fully described, illustrated and claimed.

In the embodiment of the present invention illustrated in the accompanying drawings Fig. 1 is a horizontal section of a portion of a completed external wall with cavities and a solid internal wall or partition.

Fig. 2 is a vertical section through the external wall on the line 11 of Fig. 1.

Fig. 3 is a horizontal section showing one vertical metal upright or element in position with re-usa-ble forms or concrete retaining elements attached thereto and with reinforcing steel in place, ready to receive the plastic concrete.

Figs. 4 and 5 are vertical sections of the last above respectively on the lines 3939. and 040 of Fig. 3.

Fig. 6 is a horizontal section of an arrangement of metal uprights, re-usable forms, re-

inforcing steel and permanent solid insulating cores, all assembled and ready to receive plastic concrete.

Figs. 7 and 8 are vertical sections of the ible removable core for use in forming cavities in the body of a wall.

Figs. 15 and 16 are vertical sections of the last above respectively on the lines 77 7 7 and 7878 of Fig. 14.

Fig. 17 is a horizontal section of the same core collapsed and ready for removal from the hardened concrete.

Fig. 18 is a wedge shaped removable core.

Fig. 19 is a metal anchor or tie embedded in a solid permanent insulating core.

Fig. 20 is a fragmentary sectional view showing permanent cores placed between rigid metal uprights and having open work metal secured on opposite sides and embedded in the concrete.

Similar reference numbers designate corresponding parts throughout the several drawings.

In carrying out the present invention which makes possible the economical application of monolithic concrete constructi to domestic and otln and varied desr n I purpose to employ r vertical metal in rights which are h rein 1 ferred to as metal uprights held ere L from their lower ends by various means at suitable intervals alon the axis of the wall. The primary function of these metal uprights is to readily locate and hold in position the concrete retaining: elements or forms while a secondary function of these metal uprights is the automatic spacing and the supporting of horizontal reinforcingbars when the same are required. Another function of these metal uprights is the locating and holding; in position of either temporary or permanent insulating cores should these be desired. A further function of these metal uprights is that they become emledded in the concrete and remain there as permanent reinit'orci g or take the place of all or a part of the ver tical reinforcement required.

The concrete retaining elements al mentioned may be of two varie l ies winch varieties may be either used separatei or in conjunction with one another and arer (1) Temporary removable forms of any suitable material made up in standard or stock sizes of uniform height and such various stock lengths in multiples of say three inches starting; with 18 inches so that by selecting a combination of same workman may obtain any desired length within 8 inches and any enactlength by cutting; a small filler piece to suit or this gap of 3 inches or l ss may be overcome by the use of pieces of thin sheet metal when. the imprint of same on the wall is not objectionable.

(2) Permanent metal forms or clog mesh which retains the major part of the nlcs 'z; concrete and allows a small portion of same to ooze through and more or less incase the clog mesh or permanent form, thereby bonding; the same to the body of wall and reinforcing it. These permanent forms may be of metal lath, expanded metal or wire mesh of present design and manufacture or pressly designed for this purpose i which must be suitable for ready cntti 2 bending.

In erecting walls it is intended th concrete be poured in or con or suitable height each course being allowed to suiiiciently set before proceeding higher, to give the metal uprights which will prefect above the layer or course of concrete just placed, enough rigidity for the repetition of the process.

Referring to Figs. 1 and 2: 2 is an exterior wall which has been formed with the aid of metal uprights 9, re-usable temporary forms now removed and collapsible cores also removed from the cavities 12. The method of procedure in erecting this wall is as follows :A concrete footing 4, see also Figs. 7 and S, in which are located, anchor bolts 5 and reinforcing stubs 6 is first made and allowed to harden, after which the metal uprights 9 are erected and held rigid in correct position by said anchor bolts 5 and by the aid of metal clamps 7 and metal wedges 8 and preparation is next made for the placing of the first run or course of plastic concrete as follows: The collapsible cores which are a little higher than a course of concrete are placed in the position of the cavities 12 after which the horizontal reinforcing bars 10 are placed through the metal uprights and rested there-on, the vertical reinforcing bars 11 are then set up and wired to the horizontal bars after which the temporary reusable forms are secured in a manner later described, at a suitable distance from, and on either side of, the metal upright after which the first layer or course of plastic concrete is placed. This first course of concrete is then allowed to set long enough to give sufficient rigidity and strength to the metal upright projecting above same after which the collapsible cores may be removed and the process of placing steel, cores and forms is repeated and another course of plastic concrete placed which process is repeated until the desired height of wall is obtained. It should be understood that it is not intended to erect a solitary straight wall in this manner, but that all or most of the walls of a building be erected simultaneously thus giving great rigidity and strength as the concrete attains its ultimate strength. Other references in this figure ar :13 a window opening, 14 groove to receive sash, 15 end of wall or plain jamb to opening, 16 a continuous corbel supporting timber floor 17, 18 ground line, 19 rough board or sheet metal placed over cavity before pouring more concrete above same, 20 concrete forming body of wall. 21 timber roof.

The solid wall shown at 3 Fig. 1 is erected similarly except that the forms 23 are in this case permanent metal forms which are secured direct to the metal uprights 22 and 22?), the concrete 24 is allowed to partially ooze through the forms and in this case allowed to partially set when cement plaster 26 is applied. 22b is a special upright with small holes in its web so that the concrete only oozes through in the same manner that it oozes through the permanent metal forms.

Figs. 3, 4; and 5 are enlarged views of a metal upright, similar to that shown at 9 in Figs. 1 and 2, together with reinforcing steel and temporary removable forms all shown assembled and ready to receive the first course of plastic concreie. It should be noted here that neither core nor cavity is shown, the same being optional and not an essential feature of this invention. The new notations are 9a the metal upright, in this case formed by either slotting and expanding a narrow channel section or by welding a zigzag bar between two small angle bars. 32 are heels formed by bending in a portion of the edge or flange of the upright and with which the clamp 7 engages. 33 are suitably located slots in the edges of metal uprights through which pass the bolts 34 which secure the temporary forms 35. These bolts are each provided with a washer 37 under the head and the nut 38 is placed on the inside of the metal upright thus enabling the bolt to be unscrewed and withdrawn after the con crete is set, the nut remaining in the wall and new. nuts being required each time the bolts are used, 36 are small precast blocks of concrete holding the forms at correct distance from the upright thus insuring protection of the metal upright by completely encasing it in concrete.

Figs. 6, 7 and 8 illustrate an assembly of metal uprights; which may be made 1n lengths that are readily erected one upon the top of the other as the work proceeds or 1n lengths the full height of the Wall 1f so re 'quired, together with solid permanent insulating cores, reinforcing steel and temporary reusable forms all ready to receivethe first course of concrete. Thenew notations are :-9b a section of metal upright made either from rolled channel section or narrow strips of sheet metal bent into channel form. 51 are large apertures in the upright which allows continuity of concrete lengthwise of the wall. 52 are small apertures in the upright to accommodate horizontal reinforcing bars. 53 is a tusk or lug formed at the lower end of all upper or extension sections of upright which tusk engages the section below and about which the upper section will rotate a little in a vertical plane so as to allow the upper section to be set plumb. 54 designates corresponding slots in both sections through which bolts 55 are placed'to receive and hold in position the upper section. The upper ends of all sections of this type of upright will be the same so that extending may be done as often as desired. 12a permanent insulating cores. 58 are metal anchors holding the permanent cores in position, which anchors are later described. It should be here mentioned that the permanent cores are not an essential part of this invention and also if desired the reinforcing may be applied in the form of mesh to the outsides of the metal uprights and furthermore while certain combinations of elements, cores and reinforcing are shown in each of the different illustrations it is intended that all or any of these different elements, cores and reinforcing may be used in any desired combination providing they fulfill the function allotted them where illustrated.

Fig. 9 is an enlarged horizontal section of the solid wall or partition shown at 3 in Fig. 1 while Fig. 10 is a vertical section on the line 6262 Fig. 9. The new reference numbers therein are :61 small tusks or clips integral parts of the upright so arranged that they will enter through the mesh of the permanent forms as the same is placed against the upright and that they can then be bent back so as to firmly hold the permanent forms in place. 63 is a metal bracket which can be readily clamped to the upright at any desired height and is provided with similar clipping devices for permanent forms thus enabling a cornice or corbel of any deslred shape or profile to be constructed in much the same way that the plain wall is constructed. 64L is a concrete floor or other slab of any variety or design which, while not a part of this invention, serves to illustrate how readily this invention may be applied to light weight monolithic construction. l

Figs. 11, 12, and 13 are each isometric sketches of portions of varied types of metal uprights: Fig; 11 being the same type as shown in Figs. 9 and 10' and needs no further description. Fig. 12 is made by simply bending into channel form a narrow strip of expanded metal or diamond mesh metal lath in using which the permanent forms may be simply wired to the upright. 13 is composed of two straight bars and two narrow bars bent to form continuous lattice bars the whole being either riveted or welded together.

In Figs. 14,15, 16 and 17, I show sections of collapsible core as aforementioned, the two pieces 71 forming the body or shell being in two like halves and so bent that they have to be held out by the wedging device to the normal width of core. 72 are two wedge shaped guides one secured to each half of shell, 73

V is the wedge which holds the shell pieces of core apart at the correct distance, 74; are pins which are engaged by the clips 75 which hold the shell parts together while the core is being placed in position. It will now be readily understood that after the concrete is set around this core, the upward withdrawal of the wedge 73 will allow the two wedge guides and their attached shell pieces to spring towards one another after which thetwo shell pieces may be shaken loose from the concrete and lifted out of the cavity by the lifting grip 76. i

r Fig. 18 is an isometric view of a wedge shaped removable core made of any suitable material and is provided with lifting grips 71. It should be noted that in the sketch the bevel or wedge is greatly exaggerated for clearness.

Fig. 19 shows a metal'tie or anchor 81 for holding permanent cores in position until the concrete is set and at the same time tieing together the concrete at either side of the core. The tie 81. is a simple flat metal bar twisted at the middle as at 82 and is placed in the core during .manufacture. The twisting prevents the tie from pulling out of the core or prevents the core from sliding along the tie after the tie has been bent over the reinforcing bars.

In Fig. I show a wall formed of rigid metal uprights 85, having hollow or solid, permanent cores 86 disposed therebetween and having open work metal '87 supported along both sides, said parts when embedded iin-concrete forming a wall comprising a plurality of reinforced columns connected to gether by reinforced concrete slabs extending along opposite sides of the cores.

Vhile the foregoing sets forward a preferredand practical embodiment of'the present invention it should be understood that various changes in the form, proportions and minor details of construction may be resorted to without departing from the spirit of the invention or scope of the appended claims.

I claim l. A reinforced concrete wall construction made from plastic concrete, embodying rigid metal uprights disposed at intervals along the medial plane of the wall, means for rigidly supporting said uprights from their bottom ends said means constituting the sole supporting means for the uprights until the concrete is placed and set, concrete retaining elements secured to said uprights, and horizontal reinforcing steel supported by said uprights, said uprights and said retaining elements being arranged to become permanently embedded in the finished wall thereby reinforc in; the same, said wall constituting a true reinforced monolithic structure which gains its stability the construction proceeds.

2. A reinforced concrete wall construction embodying rigid metal uprights disposed at intervals along the medial plane of a wall. means rigidly supporting said'uprights from their bottom ends, said means constituting the sole supporting means for the uprights until the concrete is placed and set and horizontal reinforcing means supported in correctly spaced position by said uprights until the con crete is set, said uprights c'o'nstit ting reinforcing members in the finished wall, said wall constituting a true reinforced monolithic structure which gains its stability as the construction proceeds.

3. A reinforced concrete Wall construction embodying rigid metal uprights disposed at intervals along the medial plane of a wall, means rigidly supporting said uprights from their bottom ends, said means constituting the sole supporting means for the uprights until the concrete is placed and set and con crete retaining elements supported in cor rectly spaced position by said uprights preparatory to the introduction and setting of the concrete, said uprights constituting reinforcing members in the finished wall, said wall constituting a true reinforced monolithic structure which gains its stability as the construction proceeds.

4, The apparatus as described in claim 3 in which the uprights are made in readily detachable sections and the finished concrete becomes the means for supporting the uprights from their bot-tom ends in a vertical position when a wall is laid in courses one on another.

5. A reinforced concrete or other plastic, fireproof material wall embodying alternately placed foraminous metal uprights, held during construction of the wall solely from their lower ends, permanent cores of substantially the same width as said uprights arranged to be placed between said uprights with the ends of the cores spaced slightly from the uprights to permit the entrance of concrete therebetween, open work metal secured to opposite sides of the metal uprights and forming concrete retaining means capable of being penetrated by concrete said uprights and said cores and said concrete retaining means all being embedded in concrete thereby forming a wall comprising a plurality of reinforced concrete columns connected together by two spaced apart reinforced concrete slabs, said wall constituting a, true reinforced monolithic structure which gains its stability as the construction proceeds.

6. The combination with a rigid metal up right for use in constructing plastic concrete walls, of a metal bracket and readily attachable means for securing said bracket at any desired height to said upright said bracket being capable of cooperating and forming by similar methods to those used for the body of the wall an integral cornice or corbel on the wall.

7. A reinforced concrete wall construction embodying rigid spaced metal uprights, and

open work metal concrete retaining elements supported by said uprights in spaced apart relation said concrete retaining elements serving to retain concrete therebetween and to permit portions of said concrete to protrude therethrough to form a plaster base, said uprights and said concrete retaining elements remaining within the finished wall and reinforcing the same.

CLAUDE BRADLEY. 

